Electrical box with adjustable mounting system

This patent application claims priority to U.S. Provisional Patent Application Ser. No. 63/491,192, filed on Mar. 20, 2023, the entire disclosure of which is hereby incorporated herein by reference.

The present invention relates to an electrical box assembly, and more particularly, to an electrical box assembly having an adjustable mounting system including a bracket and an adjusting screw that facilitates a repositioning of the electrical box with respect to the bracket, and consequently a mounting structure or surface.

Typically, an electrical box is used to support and contain electrical devices and wiring in a centralized space. The electrical box protects the wiring and electrical devices contained therein from extrinsic conditions such rain, snow, and fire, for example. A cover plate can be provided to further protect the wiring and electrical devices and militate against accidental contact with the wiring and devices. The electrical box is typically connected to a joist, a stud, or another structural component of a building acting as a mounting structure or surface.

Prior art electrical boxes include mounting systems with fastening devices that facilitate a connection to mounting structures. A common goal in installing electrical outlet boxes on interior walls is to install the front face of the box substantially flush with a wall surface. Conventional outlet boxes are typically fastened to a wall stud before the drywall is applied to the studs. As drywall is supplied in various thicknesses, it is difficult for the installer of the outlet boxes to position them correctly with respect to the eventual wall surface. If a repositioning of the electrical box is desired, the fastening devices must be completely removed from the mounting structure. The electrical box is then repositioned and the fastening devices re-fastened to the mounting structure. This typically requires the formation of additional apertures in the mounting structure. Further, the repositioning process can be time consuming.

To provide a means of adjusting the face of the outlet box substantially flush with the wall surface, adjustable outlet boxes have been proposed. The adjustable outlet boxes typically include a bracket and a mechanism for adjusting the face of the outlet box with respect to the wall surface.

Although several adjustable outlet boxes have been proposed, there is still a need for an adjustable outlet box that can be securely fastened to a stud. Additionally, brackets suggested by the prior art are typically of complex design, which increases the production costs thereof.

What is needed therefore is an adjustable electrical outlet box that is of simple design to enable it to be easily manufactured. Additionally, the adjustable outlet box should be capable of being securely fastened to a stud such that the box will not become loose from the supporting stud. These and other advantages can be realized with the adjustable outlet box proposed herein in the present invention.

Prior art adjustable outlet boxes are disclosed in U.S. Pat. Nos. 5,289,934; 7,312,395; 8,076,578; and 10,756,522, the entire disclosure of each of which is incorporated herein by reference.

It would be desirable to produce an electrical box assembly including a mounting system which facilitates a repositioning of the electrical box, wherein an case of repositioning the electrical box is maximized.

Consistent and consonant with the present invention, an electrical box assembly including a mounting system which facilitates a repositioning of the electrical box, wherein an case of repositioning the electrical box is maximized, has surprisingly been discovered.

In one embodiment, an electrical box assembly includes an electrical box having a sidewall and a front opening leading into an interior of the electrical box with the sidewall including a channel and a pair of opposing bracket-receiving openings formed therein. A bracket includes a pair of opposing wings formed thereon and at least one guide structure formed thereon with each of the wings is configured to be slidingly received in one of the opposing bracket-receiving openings. A threaded fastener is configured to be rotatably received in the channel and threadingly received in the at least one guide structure to selectively adjust a position of the bracket relative to the electrical box with respect to an axial direction of the threaded fastener.

The following description of technology is merely exemplary in nature of the subject matter, manufacture and use of one or more inventions, and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in such other applications as may be filed claiming priority to this application, or patents issuing therefrom. Regarding methods disclosed, the order of the steps presented is exemplary in nature, and thus, the order of the steps can be different in various embodiments. “A” and “an” as used herein indicate “at least one” of the item is present; a plurality of such items may be present, when possible. Except where otherwise expressly indicated, all numerical quantities in this description are to be understood as modified by the word “about” and all geometric and spatial descriptors are to be understood as modified by the word “substantially” in describing the broadest scope of the technology. “About” when applied to numerical values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” and/or “substantially” is not otherwise understood in the art with this ordinary meaning, then “about” and/or “substantially” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters.

All documents, including patents, patent applications, and scientific literature cited in this detailed description are incorporated herein by reference, unless otherwise expressly indicated. Where any conflict or ambiguity may exist between a document incorporated by reference and this detailed description, the present detailed description controls.

Although the open-ended term “comprising,” as a synonym of non-restrictive terms such as including, containing, or having, is used herein to describe and claim embodiments of the present technology, embodiments may alternatively be described using more limiting terms such as “consisting of” or “consisting essentially of.” Thus, for any given embodiment reciting materials, components, or process steps, the present technology also specifically includes embodiments consisting of, or consisting essentially of, such materials, components, or process steps excluding additional materials, components or processes (for consisting of) and excluding additional materials, components or processes affecting the significant properties of the embodiment (for consisting essentially of), even though such additional materials, components or processes are not explicitly recited in this application. For example, recitation of a composition or process reciting elements A, B and C specifically envisions embodiments consisting of, and consisting essentially of, A, B and C, excluding an element D that may be recited in the art, even though element D is not explicitly described as being excluded herein.

As referred to herein, disclosures of ranges are, unless specified otherwise, inclusive of endpoints and include all distinct values and further divided ranges within the entire range. Thus, for example, a range of “from A to B” or “from about A to about B” is inclusive of A and of B. Disclosure of values and ranges of values for specific parameters (such as amounts, weight percentages, etc.) are not exclusive of other values and ranges of values useful herein. It is envisioned that two or more specific exemplified values for a given parameter may define endpoints for a range of values that may be claimed for the parameter. For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that Parameter X may have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if Parameter X is exemplified herein to have values in the range of 1-10, or 2-9, or 3-8, it is also envisioned that Parameter X may have other ranges of values including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, 3-9, and so on.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

illustrate an electrical box assemblyaccording to an embodiment of the present invention. The electrical box assemblyincludes an electrical box, a bracketslidably engaging the electrical box, and a threaded fastenerconfigured to operably engage the bracketto adjust a position of the bracketrelative to the electrical box. The electrical box assemblyis adjustable to accommodate varying wall thicknesses, as may occur when a wall structure housing the electrical box assemblyincludes multiple layers or a non-standard thickness, such that the electrical boxmay be desirably positioned relative to an outer and exposed surface of the corresponding wall structure.

The threaded fastener(shown in isolation in) includes, with respect to an axial direction of the threaded fastener, a head, a substantially cylindrical portion, a flange or shoulder, and a threaded portion. The headis formed at a first end of the fastenerand includes a tool indentationformed in an axial end thereof, wherein the tool indentationis configured to receive a rotational tool (not shown) therein for rotating the threaded fastener about a central longitudinal axis thereof, such as receiving the operational end of a screw driver or similar tool. The cylindrical portionis formed between the headand the flangeand includes a reduced diameter in comparison to each of the headand the flange. The threaded portionextends from adjacent the flangeto a second end of the fastenerand also includes a reduced diameter in comparison to each of the headand the flange. More specifically, a thread of the threaded portionincludes a maximum outer diameter that is less than an outer diameter of either of the heador the flange.

The electrical boxincludes a back wall, a pair of opposing sidewalls, and a pair of opposing end walls, which cooperate to define a hollow interior space of the electrical boxhaving a front openingpermitting access to the interior space at a frontof the electrical box, wherein the frontforms a surface of the electrical boxarranged opposite the back wallthereof. As shown, the electrical boxis formed as a unitary structure. However, the electrical boxcan be formed from independent parts assembled together without necessarily departing from the scope of the present invention. Further, the electrical boxshown is formed from a molding process, although other forming processes can be used, as desired. The electrical boxmay be produced from a fiberglass-reinforced polyester, although other materials can be used, as desired. The electrical boxmay include knock-outs, doors, or the like for introducing electrical components into the interior of the electrical box. The electrical boxfurther includes structure for mounting additional structure to the electrical box, such as coupling features for mounting an outlet cover or the like to the frontof the electrical box, as desired.

A channelis formed in one of the opposing sidewallsof the electrical boxand is configured to receive at least a portion of the threaded fastenertherein during operational use of the electrical box assembly, as best shown in. The channelis provided as a laterally extending indentation formed in an outer surface of the corresponding one of the sidewallsthat is indented in a direction towards the interior space of the electrical box(and towards the opposing one of the sidewallsdisposed opposite the channel). As used hereinafter, the lateral direction refers to a direction extending between the opposing sidewalls, which may be a horizontal direction in accordance with an installed orientation of the electrical box assemblyaccording to the present embodiment. The channelfurther extends from the frontof the electrical boxand towards the back wallwith respect to an axial direction of the electrical box assemblyarranged perpendicular to the described lateral direction, and may extend along an entirety of an axial dimension of the electrical boxfrom the frontto the rearward surface of the back wall, as desired. The axial direction may also be a horizontal direction according to the installed orientation of the electrical box assemblyas disclosed herein. The channelincludes a varying configuration (cross-sectional shape) when extending rearwardly from the fronttowards the back walland includes, with respect to the rearwardly extending axial direction, a first portion, a second portion, and a third portion.

The first portionof the channelis formed at the frontof the electrical boxand includes a cross-section having a combination of a laterally inwardly disposed semi-circular portion and a laterally outwardly disposed rectangular portion leading into the semi-circular portion. The first portionis dimensioned to receive the headof the threaded fastenertherein during a lateral movement of the headinto the first portionof the channel, and is further dimensioned to allow for rotation of the headabout the central axis of the threaded fastenerwhen received within the first portion. The cross-sectional shape of the first portionmay be considered to be a truncated stadium shape having only one semi-circular portion disposed at the end of the corresponding rectangular portion.

The second portionof the channelis formed immediately rearwardly of the first portionthereof and includes a cross-section having a cylindrical shape arranged concentrically relative to the semi-circular portion of the cross-section of the first portion, thereby allowing for the cylindrically shaped threaded fastenerto be axially received through each of the first portionand the second portion. The cylindrical shape formed by the second portionincludes a diameter that is less than a diameter of the first portionto cause a front-facing surface of the second portionto form a first shoulderwhere the channelreduces in cross-section from the first portionto the second portion. The cylindrical shape of the second portionforms a circular arc that extends through greater than 180° of angular displacement relative to a central axis of the cylindrical shape to cause the second portionto include a mouthhaving a reduced dimension in comparison to a distance between diametrically opposing sides of the circular arc. The mouthis selected to have a slightly smaller dimension than the cylindrical portionof the threaded fastenerwhile the circular arc includes a diameter slightly greater than that of the cylindrical portion. The mouth accordinglyallows for the lateral entry of the cylindrical portionof the threaded fastenerinto the second portionof the channelin a snap-fit manner that facilitates a removable coupling of the threaded fastenerto the electrical boxand the ability to rotate the cylindrical portionwithin and relative to the second portionof the channel.

The third portionis formed immediately rearwardly of the second portionand includes an enlarged cross-section relative thereto to cause the channelto enlarge when progressing rearwardly from the second portion. This enlargement of the channelat the transition to the third portionresults in a rearward facing surface of the second portionforming a second shoulder. The third portionmay have substantially any cross-sectional shape so long as the second shoulderis formed at the transition of the channelfrom the second to third portions,, and so long as the threaded portionof the threaded fasteneris receivable within the third portionwithout intruding upon the electrical boxor interfering with operation of the bracket.

At least one bracket-receiving openingis formed on the electrical boxon the same one of the opposing sidewallsas the channel. The present embodiment includes a pair of the bracket-receiving openingswith each of the bracket-receiving openingsrespectfully formed adjacent one of the opposing end wallsof the electrical box, although it is understood that the bracket-receiving openingscan be formed at intermediate locations on the one of the opposing sidewalls, as desired, so long as the bracketengages the bracket-receiving openingsin a guiding fashion as described herein. The bracket-receiving openingsare positioned on the one of the sidewallsto opposing sides of the channelwith respect to a height direction of the electrical boxextending between the opposing end wallsthereof, wherein the height direction is perpendicular to each of the lateral direction and the axial direction. In the embodiment shown, each of the bracket-receiving openingsextends uninterrupted from the frontof the electrical boxand through the rearward surface of the back wallthereof. However, it is understood that the bracket-receiving openingscan have a length shorter than a length from the frontto the back wall, and thus be spaced from one or both of the frontand the back wall, without necessarily departing from the scope of the present invention.

Each of the bracket-receiving openingsis open in a direction towards the centrally disposed channeland includes a first segmentand a second segment, wherein each of the segments,extends axially along the length of the corresponding bracket-receiving opening. The first segmentextends from the open portion of the corresponding bracket-receiving openingtowards the second segmentand the second segmentextends away from the first segmentand forms an inwardly disposed and vertically outward end of each of the respective bracket-receiving openings. As used herein, a height direction of the electrical box assemblyrefers to a direction extending between the opposing end wallsof the electrical boxand is arranged perpendicular to each of the axial direction and the lateral direction thereof. The height direction may be a vertical direction according to the installed orientation of the electrical box assembly. As used hereinafter, references to vertically extending features of the electrical box assemblyrefer to those features extending in the described height direction of the electrical box assembly. The first segmentextends laterally inwardly towards the interior space of the electrical box(towards the opposing one of the sidewallsnot having the channeland bracket-receiving openingsformed therein) and then vertically outwardly towards a corresponding one of the end wallsto cause the first segmentof each of the bracket-receiving openingsto be arranged at an incline with respect to the lateral and vertical directions of the electrical box. Specifically, at least an outer surface of the one of the sidewallsdefining an inner disposed and outwardly facing surface of the corresponding bracket-receiving opening(facing away from the interior of the electrical box) includes a surface inclined with respect to the lateral and vertical directions. The second segmentextends in the vertical direction away from the corresponding first segmentand towards the adjacent one of the end walls. Specifically, at least the outer surface of the one of the sidewallsdefining the corresponding bracket-receiving openingincludes a surface extending exclusively in the vertical direction away from the inclined surface of the first segment

The manner in which each of the bracket-receiving openingsextends at least partially laterally inwardly towards the interior of the electrical boxand then vertically outwardly towards the adjacent one of the end wallsresults in the formation of a flanged portionof the one of the sidewallsthat forms an outer disposed and inwardly facing surface defining at least a portion of the corresponding bracket-receiving opening. That is, each of the bracket-receiving openingsis formed as an open space disposed between an inner disposed and outwardly facing surface of the one of the sidewallsand an outwardly disposed and inwardly facing surface of the corresponding one of the flanged portions. In the provided embodiment, each of the flanged portionsdefines a vertically extending and inwardly facing surface along the second segmentof the corresponding bracket-receiving opening, thereby resulting in the flanged portionbeing devoid of an inclined surface opposing that of the first segment. However, in some embodiments, the flanged portionmay further define an inwardly facing surface having an incline similar to or matching that of the incline of the one of the sidewallsalong the first segment, as desired, without necessarily departing from the scope of the present invention.

A surface of the electrical boxdefining each of the respective bracket-receiving openingsfurther includes a pair of protuberancesor interference guidesprojecting therefrom for aiding in locating and guiding the bracketrelative to the electrical box. Specifically, a surface of the corresponding sidewalldefining a corresponding one of the bracket-receiving openingsincludes a first one of the protuberancesprojecting outwardly and away from the interior space of the electrical boxalong an outward facing portion of the first segmentthereof and a second one of the protuberancesprojecting inwardly towards the interior space along an inward facing portion of the second segment, which corresponds to the inwardly facing surface of the corresponding flanged portion. Each of the protuberancesfurther extends in the axial direction of the electrical boxfrom the frontto the back wallthereof with each of the protuberancesextending substantially in parallel to the direction of axial extension of the corresponding bracket-receiving openinginto which each pair of the protuberancesprotrudes. However, each of the protuberancesmay be provided to extend along only a portion of the axial length of the corresponding one of the sidewallsand may thus be spaced from one or both of the frontand the back wall. Further as shown, the protuberanceshave a generally arcuate cross-sectional shape when projecting away from the corresponding surface, although other shapes can be used, as desired. One or both of the axial ends of each of the protuberancesmay be tapered to aid in piloting an end of a corresponding one of the wingsof the brackettherein when initially entering the bracket-receiving openings. In the illustrated embodiment, the tapered end may be formed by a quarter-sphere shape that transitions to the arcuate cross-sectional shape of each of the protuberances, although other tapered shapes may be utilized in piloting the wings. In the embodiment shown, the protuberancesextend from a position immediately adjacent the frontof the electrical boxto a position immediately adjacent the back wallof the electrical box.

The bracketmay be produced from a plated carbon steel, although other materials can be used, as desired. The bracketincludes a main bodywhich is substantially planar and plate-like in configuration. A wing(also referred to as a stepped portion) extends from each of the opposing ends of the main bodycorresponding to the vertically upper and lower ends of the main bodywhen the bracketis operatively engaging the electrical box. Each of the wingsis configured to be slidably received in one of the bracket-receiving openingsof the electrical boxduring operational use of the electrical box assembly. Each of the wingsincludes an inclined portionextending from the respective upper or lower end of the main bodyand an offset portionextending from an end of the inclined portionformed distally relative to the main body. When the bracketoperatively engages the electrical box, the inclined portionof each of the wingsis disposed at an incline with respect to each of the lateral direction and the vertical direction while the offset portionof each of the wingsis arranged in the vertical direction in parallel to the main body. Each of the inclined portionsmay include an incline substantially similar to or the same as the incline of the first segmentof the corresponding one of the bracket-receiving openings. The offset portionsof the wingsmay be arranged coplanar with each other and are offset laterally from the plane of the main bodyas a result of the extension of the inclined portionsaway from the main body.

The main bodyof the bracketfurther includes a plurality of guide structures,for guiding the axial motion of the threaded fastenerrelative to the bracketduring operational use of the electrical box assembly. The guide structures,of the present embodiment include a pair of first guide structureswith each of the first guide structuresengaging the threaded portionof the threaded fastenerto a first diametric side thereof and a second guide structureengaging the threaded portionto a second diametric side thereof opposite the first diametric side. The guide structures,project away from a surface of the main bodyfacing towards the sidewallof the electrical boxhaving the channeland the bracket-receiving openingsformed therein. The first guide structuresare positioned axially to either axial side of the second guide structureto result in an alternating configuration of the first and second guide structures,when progressing in the axial direction of the electrical box assembly.

Each of the first guide structuresis formed as a strip of the main bodyextending laterally outwardly away from the plane of the remainder of the main bodyin a substantially triangular shape for forming an apertureextending around and receiving the threaded portionof the threaded fastenertherein. The apertureformed by each of the respective first guide structuresincludes a cylindrically shaped surface at a laterally inward side thereof where the legs of the triangular shape meet at a position disposed distally from the plane of the main body, wherein each of the aperturesis configured to receive the threaded portiontherethrough for guiding axial movement of the threaded fastener.

The second guide structureis also a triangular strip of the main bodyextending laterally outwardly away from the plane of the remainder of the main bodyin similar fashion to each of the first guide structures, but the second guide structureprojects away from the plane of the main bodyby a smaller lateral distance than each of the first guide structuresto position the second guide structureto the opposing diametric side of the threaded fastenerin comparison to each of the first guides. The threaded portionof the threaded fasteneris axially receivably through each of the aperturesof the first guide structuresand along the exposed surface of the second guide structureto constrain the threaded portionto move only axially relative to the bracket., which includes an enlarged view of the first and second guide structures,, illustrates the threaded fastenerin broken line format to show the manner in which the threaded portionthereof may be received between the diametrically opposing surfaces of the first and second guide structures,to constrain the threaded fastenerto move axially along the central axis thereof, which coincides with the axial direction of the electrical box assemblywhen the threaded fasteneris operatively engaging the electrical boxand the bracket.

As shown in, at least one thread engaging projectionmay project from a facing surface of one or more of the guide structures,for engaging the thread of the threaded portionof the fastener. Specifically, one or both of the first guide structuresmay include one of the thread engaging projectionsdisposed along the cylindrically shaped surface thereof for engaging the first diametric side of the threaded portionand the second guide structuremay include one of the thread engaging projectionsdisposed along a distal surface of the second guide structurefor engaging the second diametric side of the threaded portion. Each of the thread engaging projectionsis configured to be receivable between adjacent and axially spaced apart segments of the thread of the threaded portionsuch that rotation of the threaded fastenerabout the central axis thereof results in an axial pushing of each of the thread engaging projectionsin a forward or rearward axial direction, depending on the direction of rotation of the threaded fastener (clockwise or counterclockwise). In the example shown in, each of the guide structures,includes one of the thread engaging projections, but it should be apparent that fewer or more of the thread engaging portionsmay be utilized while remaining within the scope of the present invention, including the use of only a single one of the thread engaging projectionson only one of the guide structures,.

The main bodymay include one or more aperturesto facilitate insertion of fasteners (not shown) to couple the main bodyto a support structure such as a joist, a stud, or another structural component of a building acting as a mounting structure or surface. The main bodymay include any configuration and number of the aperturesfor establishing a desired coupling of the bracketto the corresponding support structure.

In some embodiments, an angled bodyextends from the main body, wherein the angled bodymay be provided as a substantially planar and plate-like structure. The main bodyand the angled bodymay be formed from a single piece of material, although the main bodyand the angled bodycan be formed from separate pieces of material and coupled to each other by any known fastening method, as desired. If formed from a single piece of material, the bracketmay be formed as a planar blank arranged on the plane of the main body, and may be subsequently bent to form the bracketas shown throughout the figures. Specifically, the angled bodymay be provided to extend from an axial end of the main bodydisposed towards the frontof the electrical box. Further, in the embodiment shown, an angle of 90 degrees is formed between the main bodyand the angled body, although other angles can be provided to accommodate differing mounting configurations.

Aperturesmay be provided in the angled bodyto facilitate insertion of fasteners (not shown) to couple the angled bodyto a support structure such as a joist, a stud, or another structural component of a building acting as a mounting structure or surface. The angled bodymay include any configuration and number of the aperturesfor establishing a desired coupling of the bracketto the corresponding support structure.

The angled bodymay further include at least one bendable tabthat is able to be bent from a configuration wherein the bendable tabis arranged co-planar to the plane of the angled bodyto a configuration wherein the bendable tabis arranged transverse relative to the plane of the angled body, such as being arranged perpendicular relative to the plane of the angled body. Each of the tabsmay be disposed at a distance from the main bodysufficient for receiving the support structure to which the bracketis coupled between a face of each of the tabsand the facing surface of the main body. That is, the support structure, such as a stud, joist, etc., may be sandwiched between each of the bent tabsand the main body. However, the bendable tabsmay be maintained in the parallel and co-planar configuration (absent bending) where the corresponding support structure would otherwise interfere with the angled body, such as a support structure having a relevant dimension greater than a distance present between a base of each of the bendable tabsand the main bodysuch that a sandwiching of the support structure is not readily achievable.

To assemble the electrical box assembly, the cylindrical portionof the threaded fasteneris snapped into the relatively narrow second portionof the channelwith the headreceived within the first portionthereof and the threaded portionreceived within the third portionthereof. The wingsof the main bodyof the bracketare then inserted into the bracket-receiving openingsof the electrical box, which may include the wingsentering the bracket-receiving openingsin a forward axial direction with the wingsat the rear wallof the electrical boxsuch that the bracketis slid axially towards the opposing frontof the electrical box. The bracketcan then be slid towards the fasteneruntil the second end thereof including the threaded portionis received into a first one of the guide structures,, which in the present embodiment includes the threaded portionpassing through one of the aperturesdefined by a corresponding one of the first guide structures.

During and after insertion of the bracketinto the bracket-receiving openingsof the electrical box, the protuberancesabut a surface of the bracket. Thus, the protuberancesensure a snug fit between the electrical boxand the bracket. The snug fits helps minimize any relative movement between the electrical boxand the bracket, which helps minimize and noise, damage, or wobble. More specifically, as best shown in, the laterally inward facing protuberanceformed along the second segmenton the flanged portionof the corresponding one of the bracket-receiving openingsengages the offset portionof the corresponding wingalong a laterally outward facing surface thereof while the laterally outward facing protuberanceformed along the first segmenton the corresponding sidewallengages the inclined portionof the corresponding wingalong a laterally inward facing surface thereof. The engagement of each of the wingswith oppositely arranged ones of the protuberancesmay result in a partial and substantially elastic bending/deformation of one or both of the bracketor the electrical boxadjacent the engaging surfaces to ensure the previously described snug fit due to the increased friction generated by the tight fit of the corresponding wingbetween the opposing protuberances.

The threaded fasteneris then rotated to threadingly engage the thread engaging projectionsformed on one or more of the guide structures,and/or the main bodyof the bracketto further slide the bracketto a desired axial position with respect to the electrical box. In embodiments without the angled body, the main bodyis coupled to the structural support. In the embodiments including the angled body, the angled bodycan be coupled to the structural support in addition to or in place of the main body. Further adjustment to the position of the electrical boxwith respect to the bracketand the corresponding structural support can be made as desired to ensure proper positioning and alignment with the structural support or other structures such as dry wall or other building materials. Accordingly, the electrical box assemblyincludes a mounting system which facilitates repositioning of the electrical box, wherein an ease of repositioning the electrical boxis maximized.

illustrates one exemplary and non-limiting use of the electrical box assemblywherein an adjustment of the axial position of the electrical boxrelative to the bracketmay be desirable. The provided example includes a wall structurecomprising an inner layerand an outer layerstacked upon one another, wherein each of the layers,may be representative of any form of building material suitable for forming the wall structure. In one non-limiting example, the inner layeris a layer of drywall while the outer layeris a layer of paneling or the like disposed on the inner layer. The addition of the outer layerto the inner layer, which may result in a non-standard thickness of the resulting wall structure, may result in the need to adjust the electrical boxto bring the frontof the electrical boxto a position adjacent or flush to the exposed surface of the outer layer.

In the provided example, the bracketis disposed at a position wherein the bracketmay be coupled to the corresponding support structure, which may be representative of a studassociated with the wall structure, via the passage of fasteners through the apertures,of either of the main bodyor the angled body(or both), each of which may be positioned immediately adjacent or in contact with a corresponding side surface of the support structure. Additionally, the support structureis shown as being disposed laterally between the main bodyof the bracketand the at least one bendable tabwhen the at least one tabis bent perpendicular to the plane of the angled bodyand in parallel to the plane of the main body. It can be seen by a comparison oftothat the brackethas been adjusted to move axially towards the frontof the electrical boxuntil a distance between the angled bodyof the bracketand the frontof the electrical boxis substantially equal to a thickness of the combined wall structurecomprising the inner and outer layers,, thereby aligning the frontof the electrical boxwith the exposed surface of the wall structureformed by the outermost surface of the outer layer.

It should be readily apparent to one skilled in the art that the disclosed electrical box assemblymay be installed relative to a wall structure and corresponding support structure having substantially any orientation, such as forming a floor structure or ceiling structure, as desired. Such configurations may include the axial direction of the electrical box assemblybeing vertically arranged while the lateral and height directions thereof are arranged horizontally. It should also be apparent that the electrical box assemblyneed not be installed when in the disclosed upright orientation, and may be rotated to accommodate any desired installation configuration. For example, the electrical box assemblymay be installed relative to a horizontally extending support structure with the described height direction horizontally arranged and the described lateral direction vertically arranged. The illustrated orientation of the electrical box assemblyis thus non-limiting.

The bracketas disclosed herein may be manufactured from a substantially planar and plate-like blank (not shown) having the guide structures,projecting from an inboard region thereof, wherein the wingsand the angled bodyare formed by bending peripheral portions of the blank to the disclosed configuration. Specifically, the angled bodymay be bent to a desired angle relative to the main bodyalong one bend region and each of the wingsmay be bent twice along two spaced apart bend regions to form the inclined and offset portions,thereof. The described bendable tabsmay also be initially disposed on the plane of the blank and may be bent away therefrom along respective bend regions thereof. However, the bracketmay be formed into the disclosed configuration utilizing alternative methods, as desired.

From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions.